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WO2017045306A1 - 薄板焊接机器人 - Google Patents

薄板焊接机器人 Download PDF

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Publication number
WO2017045306A1
WO2017045306A1 PCT/CN2015/099558 CN2015099558W WO2017045306A1 WO 2017045306 A1 WO2017045306 A1 WO 2017045306A1 CN 2015099558 W CN2015099558 W CN 2015099558W WO 2017045306 A1 WO2017045306 A1 WO 2017045306A1
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Prior art keywords
emitting diode
image
light
welding
thin
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English (en)
French (fr)
Inventor
张炯
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Suzhou Vr Robot Technology Co Ltd
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Suzhou Vr Robot Technology Co Ltd
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Publication of WO2017045306A1 publication Critical patent/WO2017045306A1/zh
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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00Arc welding or cutting
    • B23K9/12Automatic feeding or moving of electrodes or work for spot or seam welding or cutting
    • B23K9/127Means for tracking lines during arc welding or cutting
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K37/00Auxiliary devices or processes, not specially adapted for a procedure covered by only one of the other main groups of this subclass

Definitions

  • the present invention relates to a visual sense of a butt weld to a sheet metal structure for use in robotics or automated welding, and more particularly to a welding robot.
  • the technical problem to be solved by the present invention is to provide a thin-plate welding robot which can solve any of the above problems.
  • a thin-plate welding robot characterized in that it comprises:
  • a welding gun the welding gun is disposed on the robot arm, so that the welding gun is used to weld the thin plate as the robot arm moves;
  • a video camera comprising an image sensor for acquiring the sheet and/or weld image and an electronic shutter for controlling the image sensor to acquire an image
  • Active illumination comprising a light emitting diode for providing light to the video camera, the light emitting diode operating based on the electronic shutter action.
  • the light emitting diode is a high power light emitting diode.
  • the light emitting diode causes the image sensor to acquire an image based on the electronic shutter Kai.
  • the light emitting diode is turned off based on the electronic shutter such that the image sensor does not acquire an image.
  • the light emitting diode adjusts the intensity of light emitted by the image sensor based on the image acquired by the image sensor
  • the video camera, the light emitting diode and the welding torch are arranged in a line.
  • the video camera and the light emitting diode are located in front of the moving direction of the welding torch.
  • the present invention employs the above-described apparatus, and can reliably identify butt welds (including welds having no gaps and a certain gap) of sheets in various cases without occurrence of recognition failure.
  • FIG. 1 is an apparatus for using the weld seam detecting method in the present application.
  • FIG. 2 is an image of an aluminum plate butt weld joint obtained by a welding robot of the prior art without active illumination.
  • FIG. 3 is an image of active welding of an aluminum plate butt weld joint obtained by a welding robot in the present application.
  • FIG. 4 is an image of a gapless butt weld inspection result of a 3 mm thick aluminum plate obtained by a welding robot in the present application.
  • FIG. 5 is an image of a gapless butt weld inspection result of a 3 mm thick steel plate obtained by a welding robot in the present application.
  • FIG. 6 is an image of the result of the detection of the butt weld of the scratched 3 mm thick steel plate obtained by the welding robot in the present application.
  • FIG. 8 is a test result of a 0.02 mm butt weld of a 3 mm thick aluminum plate obtained by a welding robot in the present application. Image.
  • FIG. 9 is an image of a test result of a butt weld of a 0.05 mm gap of a 3 mm thick aluminum plate obtained by a welding robot in the present application.
  • FIG. 10 is an image of a 0.3 mm butt weld inspection result of a 3 mm thick steel plate gap obtained by a welding robot in the present application.
  • FIG. 11 is an image of a 0.5 mm butt weld inspection result of a 3 mm thick steel plate obtained by a welding robot in the present application.
  • the present invention discloses a weld seam detecting method that includes the following steps:
  • the row direction of the initial image is substantially perpendicular to the weld seam, and one row is selected every n rows for processing, and m rows are selected.
  • m is a positive integer greater than 8
  • n is an integer greater than or equal to 0
  • f(i,j) represents the pixel gray value of the i-th point of the j-th row
  • the upper left corner of the image is defined as The origin is defined by the origin downward as the Y direction; from the origin to the right is defined as the X direction; the direction of the row is parallel to the X direction, and the direction of the column is parallel to the ⁇ direction.
  • a row may be selected every m rows along the ⁇ direction for sampling.
  • m may be any one of 0 to 10.
  • the origin of the coordinates is in the upper left corner of the image, the X direction is horizontal to the right, and the Y direction is vertical downward.
  • f(i,j) represents the pixel gray value of the i-th point of the jth line. If you take a line every other line, you will get 256 lines in the end. If you take a line every 3 lines, you will get 128 lines.
  • the gray difference values, f(i, j) and f(il, j) are the gray values at the pixel points (i, j) and (il, j), respectively.
  • the position of the k maxima pixels and the position of the k minima pixels are selected in the differential data.
  • k is a positive integer of any one of 2 to 4.
  • Hough Transform p Xcos6 + Ysine for 2k points (2k*m total) on all selected lines.
  • the parameters p and ⁇ uniquely determine a straight line, the distance from the p origin to the line, and ⁇ is the angle between the normal of the line and the X axis.
  • the line corresponding to this maximum value is our candidate weld line (the physical area corresponding to the image is approximately l l.2mm X l l.2mm, in the entire image range) It is assumed that the weld is a straight line.
  • the above weld inspection algorithm can not only reliably detect butt welds without gaps and small gaps, but also has strong detection results in the case of strong disturbances such as surface scratches and tack welds.
  • the identification system employed by the present invention can also verify the weld.
  • a weld seam verification method comprising the following steps: [0053] obtaining a weld image and a weld line to be verified in the weld image;
  • the obtained weld line is adjusted by the distance between the maximum value and the minimum value. .
  • the test results are adjusted.
  • the position of the largest value here corresponds to the left edge of the gap, and the position of the minimum corresponds to the right edge of the gap.
  • the difference between the maximum and minimum position corresponds to the gap width.
  • the image of 512X512 in our experiment corresponds to the physical size of 11.2mm X 12.2mm, so 0.2mm corresponds to 9 pixels.
  • a gap of 0.5 mm corresponds to 22 pixels.
  • the present application also discloses a thin-plate welding robot, which includes:
  • a robot arm having a plurality of degrees of freedom
  • a welding gun 1 the welding gun 1 is disposed on the robot arm, so that the welding gun 1 can be used for welding the thin plate as the robot arm moves;
  • a video camera 2 comprising an image sensor for acquiring the sheet and/or weld image and an electronic shutter for controlling the image sensor to acquire an image;
  • Active illumination 3 comprising a light emitting diode for providing illumination to the video camera 2, the light emitting diode operating based on the electronic shutter action.
  • the robot arm can have six or more degrees of freedom to precisely control the trajectory of the welding gun 1.
  • the welding torch 1 is controlled by the robot arm so that the thin plate can be selectively manipulated, such as welding or stopping Stop welding.
  • the welding torch can be a similar device that can be used for welding, such as a argon arc welding torch.
  • the video camera 2 has a high resolution and a small size, and is suitable for use by a robot.
  • the video camera 2 includes a high-precision image sensor that is controlled by an electronic shutter to acquire an image of the thin plate.
  • the active illumination 3 employs a high power light emitting diode. Since the light emitting diode can be controlled by an electrical signal, the light emitting diode can be controlled based on the electronic shutter. For example, when the electronic shutter manipulates the image sensor to acquire an image, the light emitting diode can provide illumination to the area of the thin plate weld, thereby providing the obtained thin plate weld image with appropriate brightness.
  • the active illumination used in the prior art is a conventional illumination lamp, and its gate control often has a certain degree of delay, and thus is not suitable for high precision and fast occasions.
  • the thin-plate welding robot in the present application can quickly process the thin plate, greatly increasing its accuracy and maneuverability.
  • the light emitting diode is a high power light emitting diode.
  • the light emitting diode causes the image sensor to acquire an image based on the electronic shutter
  • the light emitting diode is turned off based on the electronic shutter such that the image sensor does not acquire an image.
  • the light emitting diode adjusts the intensity of light emitted by the image sensor based on the image acquired by the image sensor
  • the video camera 2, the light emitting diode and the welding gun are arranged in a line.
  • the video camera 2 and the light emitting diode are located in front of the moving direction of the welding torch

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Mechanical Engineering (AREA)
  • Optics & Photonics (AREA)
  • Plasma & Fusion (AREA)
  • Length Measuring Devices By Optical Means (AREA)

Abstract

一种薄板焊接机器人,它包括机器手臂,其具有多个自由度;焊枪(1),所述焊枪(1)设置在所述机器手臂上,从而能随着所述机器手臂运动,所述焊枪(1)用于对所述薄板进行焊接;视频摄像机(2),其包括用于获取所述薄板和/或焊缝图像的图像传感器和用于控制所述图像传感器获取图像的电子快门;主动照明(3),所述主动照明(3)包括用于向所述视频摄像机(2)提供照明的发光二极管,所述发光二极管基于所述电子快门动作而动作。采用上述装置,可以对各种情形的薄板的对接焊缝可靠识别,而不会发生识别失败的情况。

Description

技术领域
[0001] 本发明涉及一种用于机器人或自动化焊接中对金属薄板结构对接焊缝的视觉识 另 |J, 尤其涉及一种焊接机器人。
背景技术
[0002] 薄板结构的无间隙对接接头在航空航天工业中应用很广, 对此类接头的自动识 别和跟踪要求也非常迫切。 人们采用了多种方法对此进行了研究, 如激光扫描 测距方法和光强分析方法、 图像分析方法以及电磁传感器方法等。 目前这些研 究工作与实际应用还有较大距离。 因为这些方法几乎都假设接头有一定的间隙 、 错边或倾斜特征, 而实际中的接头状况难以满足要求。 例如, 现有的焊缝具 有各种不同的对接焊缝的情形, 比如, 有的地方有小的间隙, 有的地方间隙稍 大一点, 另外的地方完全没有间隙。 所以现有的方法满足不了实际的需求。
[0003] 发明内容
[0004] 为了克服现有技术的上述缺陷, 本发明所要解决的技术问题是提供一种薄板焊 接机器人, 其能解决上述问题中的任一种。
[0005] 为达到上述目的, 本发明的技术方案是:
[0006] 一种薄板焊接机器人, 其特征在于, 它包括:
[0007] 机器手臂, 其具有多个自由度;
[0008] 焊枪, 所述焊枪设置在所述机器手臂上, 从而能随着所述机器手臂运动, 所述 焊枪用于对所述薄板进行焊接;
[0009] 视频摄像机, 其包括用于获取所述薄板和 /或焊缝图像的图像传感器和用于控 制所述图像传感器获取图像的电子快门;
[0010] 主动照明, 所述主动照明包括用于向所述视频摄像机提供光的发光二极管, 所 述发光二极管基于所述电子快门动作而动作。
[0011] 优选地, 所述发光二极管为大功率发光二极管。
[0012] 优选地, 所述发光二极管基于所述电子快门使得所述图像传感器获取图像而幵 启。
[0013] 优选地, 所述发光二极管基于所述电子快门使得所述图像传感器不获取图像而 关闭。
[0014] 优选地, 所述发光二极管基于所述图像传感器获取的图像而调节其发出的光强
[0015] 优选地, 所述视频摄像机、 所述发光二极管和所述焊枪沿线性排布。
[0016] 优选地, 所述视频摄像机和所述发光二极管位于所述焊枪的移动方向的前方。
[0017] 本发明采用上述装置, 可以对各种情形的薄板的对接焊缝 (包括无间隙和有一 定间隙的焊缝) 可靠识别, 而不会发生识别失败的情况。
[0018] 附图说明
[0019] 在此描述的附图仅用于解释目的, 而不意图以任何方式来限制本发明公幵的范 围。 另外, 图中的各部件的形状和比例尺寸等仅为示意性的, 用于帮助对本发 明的理解, 并不是具体限定本发明各部件的形状和比例尺寸。 本领域的技术人 员在本发明的教导下, 可以根据具体情况选择各种可能的形状和比例尺寸来实 施本发明。
[0020] 图 1为本申请中采用该焊缝检测方法的装置。
[0021] 图 2为采用现有技术中的焊接机器人获取的铝板对接焊缝焊接吋没有主动照明 的图像。
[0022] 图 3为本申请中焊接机器人获取的铝板对接焊缝焊接吋有主动照明的图像。
[0023] 图 4为本申请中焊接机器人获取的 3mm厚铝板无间隙对接焊缝检测结果的图像
[0024] 图 5为本申请中焊接机器人获取的 3mm厚钢板无间隙对接焊缝检测结果的图像
[0025] 图 6为本申请中焊接机器人获取的 3mm厚钢板无间隙有人为划痕对接焊缝检测 结果的图像。
[0026] 图 7为本申请中焊接机器人获取的 3mm厚钢板无间隙有定位焊点对接焊缝检测 结果的图像。
[0027] 图 8为本申请中焊接机器人获取的 3mm厚铝板间隙 0.02mm对接焊缝检测结果的 图像。
[0028] 图 9为本申请中焊接机器人获取的 3mm厚铝板间隙 0.05mm对接焊缝检测结果的 图像。
[0029] 图 10为本申请中焊接机器人获取的 3mm厚钢板间隙 0.3mm对接焊缝检测结果的 图像。
[0030] 图 11为本申请中焊接机器人获取的 3mm厚钢板间隙 0.5mm对接焊缝检测结果的 图像。
[0031] 以上附图的附图标记为: 1、 焊枪; 2、 视频摄像机; 3、 主动照明。
[0032] 具体实施方式
[0033] 结合附图和本发明具体实施方式的描述, 能够更加清楚地了解本发明的细节。
但是, 在此描述的本发明的具体实施方式, 仅用于解释本发明的目的, 而不能 以任何方式理解成是对本发明的限制。 在本发明的教导下, 技术人员可以构想 基于本发明的任意可能的变形, 这些都应被视为属于本发明的范围。
[0034] 本发明公幵了一种焊缝检测方法, 它包括以下步骤:
[0035] 获取焊缝图像;
[0036] 在获取的焊缝图像中, 初始图像的行方向大致垂直于焊缝, 每隔 n行选取一行 进行处理, 共选取 m行。 这里 m为大于 8的正整数, n为大于或等于 0的整数; f(i,j) 表示了第 j行的第 i个点的像素灰度值;
[0037] 对选取的行进行平滑处理;
[0038] 对平滑处理后的数据做一阶差分;
[0039] 在差分后的数据中选取 k个极大值像素的位置和 k个极小值像素的位置, 其中 k 为 2至 4;
[0040] 在对上一步中 2k个位置的每一个的邻域内寻找一个灰度极小值的位置,得到 2k 个新的位置;
[0041] [0002]对所有选取的行上的 2k个点 (共 2k*m) , 做豪尔 (Hough Transform) 变 化, 得到p = XCOSθ + YSinθ, 其中 p原点到直线的距离, Θ是该直线的法线与 X轴 的夹角;
[0042] [0002]具体地, 在本实施方式中, 在获取薄板图像后, 将图像的左上角定义为 原点, 由原点向下定义为 Y方向; 由原点向右定义为 X方向; 行的方向平行于 X 方向, 列的方向平行于 Υ方向。
[0043] [0002]为了加快处理速度, 可以在沿 Υ方向, 每隔 m行选取一行进行采样。 在本 实施方式中, m可以为 0至 10中的任一个数。 例如, 一幅灰度图像如果取样为 512 X 512个点的矩阵的话, 共有 262144个点, 每一个点有一个灰度值, 或者叫亮度 值。 坐标的取法: 坐标原点在图像的左上角, X方向为水平向右, Y方向为垂直 向下。 这里 f(i,j)就表示了第 j行的第 i个点的像素灰度值。 如果每隔 1行取一行的话 , 最后就是取得 256行, 如果每隔 3行取一行的话, 最后就是取得 128行。
[0044] 对采样得到的行进行平滑处理, 平滑窗口为 3X1。
[0045] 其中, 在对选取的行进行平滑处理, 平滑处理的公式为 f(i)=(f(i-l)+f(i)+f(i+l))/3
[0046] 对平滑处理后的数据做一阶差分, d(i,j) =f(i,j)-f(i-l,j), 这里 d(i,j)是像素点 (i,j)处 灰度差分值, f(i,j)和 f(i-l,j)分别是像素点 (i,j)和 (i-l,j)处的灰度值。 在差分后的数 据中选取 k个极大值像素的位置和 k个极小值像素的位置。 在本实施方式中, k = 为 2至 4中的任一个正整数。
[0047] 在对上一步中 2k个位置的每一个的邻域内寻找一个灰度极小值的位置,得到 2k 个新的位置。 这里邻域半径的选择取实际假设的最大间隙宽度一半对应的像素 数。
[0048] 对所有选取的行上的 2k个点 (共 2k*m) 做豪尔 (Hough Transform) p = Xcos6 + Ysine。 参量 p和 Θ唯一地确定了一条直线, p原点到直线的距离, Θ是该直线的 法线与 X轴的夹角。
[0049] 在变换后的数组中搜索最大值, 这个最大值对应的直线, 就是我们候选的焊缝 直线 (图像对应的物理区域大概在 l l.2mm X l l.2mm, 在整个图像的范围内假设 焊缝是直线是成立的) 。
[0050] 以上焊缝检测算法不仅能够可靠地检测出无间隙和小间隙的对接焊缝, 而且在 有强烈的干扰如表面划痕、 定位焊点的情况下, 检测结果也非常可靠。
[0051] 在经过焊缝检测后, 本发明采用的识别系统还可以对焊缝进行验证。
[0052] 一种焊缝验证方法, 它包括以下步骤: [0053] 获取焊缝图像以及在焊缝图像中待验证的焊缝直线;
[0054] 在原始图像的每一行与待验证的焊缝直线相交的点的两边各选取 q个像素点组 成图像子集, 初始图像的行方向大致垂直于焊缝, 其中 q=32;
[0055] 将所述图像子集的所有行相加得到一个数组, 对此数组做一阶差分并找到最大 值和最小值的位置, 差分公式为 D(i) =f(i)-f(i-l) ;
[0056] 如果最大值和最小值的位置位于待验证的焊缝直线的两侧, 则判定待验证焊缝 位置是可靠的;
[0057] 如果最大值和最小值的位置不是位于待验证的焊缝直线的两侧, 则判定待验证 焊缝位置是不可靠的。
[0058] 当所得的最大值与最小值位置之间的距离大于事先设定的需调整的焊缝间隙宽 度吋, 用最大值与最小值位置之间的的距离对所得的焊缝直线进行调整。 具体 地, 我们实际实验中, 如果焊缝间隙大于 0.2mm,检测结果就做调整。 这里最大 值的位置对应间隙的左边缘, 最小值的位置对应间隙的右边缘。 最大值和最小 值位置的差值对应与间隙宽度。 我们的实验中 512X512的图像对应于物理尺寸 11 .2mm X 12.2mm, 所以 0.2mm对应于 9个像素。 0.5mm的间隙就对应于 22个像素。 在计算出最大值和最小值像素的位置间距后, 就可以根据前面求图像子集以及 图像像素与物理尺寸的关系反推算出新的值。
[0059] 参照图 1所示, 本申请还公幵了一种薄板焊接机器人, 它包括:
[0060] 机器手臂, 其具有多个自由度;
[0061] 焊枪 1, 所述焊枪 1设置在所述机器人手臂上, 从而能随着所述机器手臂运动, 所述焊枪 1用于对所述薄板进行焊接;
[0062] 视频摄像机 2, 其包括用于获取所述薄板和 /或焊缝图像的图像传感器和用于控 制所述图像传感器获取图像的电子快门;
[0063] 主动照明 3, 所述主动照明 3包括用于向所述视频摄像机 2提供照明的发光二极 管, 所述发光二极管基于所述电子快门动作而动作。
[0064] 具体地, 在本实施方式中, 机器手臂可以具有六个甚至更多个自由度, 以对焊 枪 1的运行轨迹进行精确控制。
[0065] 焊枪 1受控于机器手臂, 从而可以对薄板进行选择性地操纵, 例如焊接或者停 止焊接。 焊枪可以为氩弧焊枪等其他类似可以用于焊接的装置。
[0066] 视频摄像机 2的分辨率高, 体积小, 适合机器人使用。
[0067] 视频摄像机 2包括高精度的图像传感器, 图像传感器受控于电子快门以对薄板 进行图像的获取。
[0068] 在本实施方式中, 主动照明 3采用大功率的发光二极管。 由于发光二极管可以 受控于电信号, 从而发光二极管可以基于电子快门而控制。 例如, 当电子快门 操纵图像传感器获取图像吋, 发光二极管可以向薄板焊缝的区域提供照明, 从 而使获取的薄板焊缝图像具有合适的亮度。
[0069] 而现有技术中采用的主动照明为传统的照明灯, 其幵关控制常常有一定程度的 延迟, 因而不适用于高精度的、 快速的场合。
[0070] 相反的, 本申请中的薄板焊接机器人, 可以对薄板进行快速处理, 大大增加了 其精度和可操纵性。
[0071] 优选地, 所述发光二极管为大功率发光二极管。
[0072] 优选地, 所述发光二极管基于所述电子快门使得所述图像传感器获取图像而幵
[0073] 优选地, 所述发光二极管基于所述电子快门使得所述图像传感器不获取图像而 关闭。
[0074] 优选地, 所述发光二极管基于所述图像传感器获取的图像而调节其发出的光强
[0075] 优选地, 所述视频摄像机 2、 所述发光二极管和所述焊枪沿线性排布。
[0076] 优选地, 所述视频摄像机 2和所述发光二极管位于所述焊枪的移动方向的前方
[0077] 比对图 2所示, 结合图 3至图 11示出, 采用本申请中的焊接机器人获取的图像清 晰度较高。
[0078] 本说明书中的各个实施例均采用递进的方式描述, 每个实施例重点说明的都是 与其他实施例的不同之处, 各个实施例之间相同相似的部分互相参见即可。
[0079] 上述实施例只为说明本发明的技术构思及特点, 其目的在于让熟悉此项技术的 人士能够了解本发明的内容并据以实施, 并不能以此限制本发明的保护范围。 凡根据本发明精神实质所作的等效变化或修饰, 都应涵盖在本发明的保护范围 之内。

Claims

权利要求书
一种薄板焊接机器人, 其特征在于, 它包括:
机器手臂, 其具有多个自由度;
焊枪, 所述焊枪设置在所述机器手臂上, 从而能随着所述机器手臂运 动, 所述焊枪用于对所述薄板进行焊接;
视频摄像机, 其包括用于获取所述薄板和 /或焊缝图像的图像传感器 和用于控制所述图像传感器获取图像的电子快门;
主动照明, 所述主动照明包括用于向所述视频摄像机提供光的发光二 极管, 所述发光二极管基于所述电子快门动作而动作。
2.根据权利要求 1所述的薄板焊接机器人, 其特征在于, 所述发光二 极管为大功率发光二极管。
根据权利要求 1所述的薄板焊接机器人, 其特征在于, 所述发光二极 管基于所述电子快门使得所述图像传感器获取图像而幵启。
根据权利要求 1所述的薄板焊接机器人, 其特征在于, 所述发光二极 管基于所述电子快门使得所述图像传感器不获取图像而关闭。
根据权利要求 1所述的薄板焊接机器人, 其特征在于, 所述发光二极 管基于所述图像传感器获取的图像而调节其发出的光强。
根据权利要求 1所述的薄板焊接机器人, 其特征在于, 所述视频摄像 机、 所述发光二极管和所述焊枪沿线性排布。
权利要求 6所述的薄板焊接机器人, 其特征在于, 所述视频摄像机和 所述发光二极管位于所述焊枪的移动方向的前方。
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